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Summary of Contents for Guyson KS MK3 300
- Page 1 The KS/UCR MK3 Range Operation & Maintenance Manual Guyson International Limited Snaygill Industrial Estate Keighley Road Skipton North Yorkshire BD23 2QR Tel: 01756 799911 E-mail: info@guyson.co.uk Fax: 01756 790213 Website: www.guyson.co.uk...
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Page 2: Table Of Contents
Operation & Maintenance Manual Table of Contents Manual content disclaimer ........................4 1. Introduction ............................5 2. Safety ..............................6 2.1 Hazards ............................6 2.2 Precautions ........................... 6 2.3 Cleaning solutions ......................... 7 2.3.1 Type ............................7 2.3.2 Use of cleaning solutions ....................... 7 2.4 Safe practices .......................... - Page 3 Operation & Maintenance Manual 8.4 Trouble-shooting guide ....................... 39 9. Principles & advantages of ultrasonic cleaning ................40 9.1 Basic principles of ultrasonic cleaning ..................40 9.2 Advantages of ultrasonic cleaning ....................41 9.3 Solution de-gassing ........................41 10. Primewave Ultrasonic Generator Manual (KS 3000 & KS 4000 only) ..........42 Issue: A6ML0260 - KS MK3 &...
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Page 4: Manual Content Disclaimer
Although our intent is to provide complete and accurate information, Guyson International Ltd. does not warrant the accuracy or completeness of the materials and content contained in this manual and reserves the right to correct any errors or omissions to the manual content at any time. -
Page 5: Introduction
Manual 1. Introduction This manual contains the information required to operate and maintain: The KS MK3 Range of Ultrasonic Cleaning Tanks: Models: KS MK3 300 KS MK3 450 KS MK3 525 KS MK3 1500 KS MK3 3000 KS MK3 4000... -
Page 6: Safety
If such personnel are not available, reference must be made to the service department of Guyson International Limited for assistance. 2.2 Precautions Observance of the following points is essential for the safe operation of the equipment: •... -
Page 7: Cleaning Solutions
If such cleaning is contemplated, it is essential to refer the matter to Guyson International, since there is a real need to confirm the compatibility of the product with the equipment, so that corrosion is avoided. -
Page 8: Safe Practices
85dB(A) (Leq) (reference The Noise at Work Regulations 1989). Before leaving the Guyson factory, each unit is checked to ensure that the noise from the equipment is below the statutory level under typical operating conditions. There is a need for users to ensure that the noise intensity does not increase with time during routine use. -
Page 9: Environmental
Operation & Maintenance Manual 2.6 Environmental To ensure minimum environmental impact the KS MK3 & UCR MK3 cleaning systems are specifically designed for aqueous based cleaning solutions, i.e. they do not use chemicals which may directly deplete the ozone layer. However, in order to prevent possible contamination of water supplies, sewers etc, all waste solutions should be disposed of in accordance with Local Water Authority regulations. -
Page 10: Installation And Siting
Operation & Maintenance Manual 3. Installation and siting In order to ensure efficient operation of the system and to maintain a safe working environment for associated personnel, it is imperative that the following conditions are met: • The unit must be sited in a dry, draught-free well ventilated area, with a clearance of 600mm on all sides, see diagram below. -
Page 11: Isolation And Switching Devices (3 Phase Units)
Operation & Maintenance Manual 3.1 Isolation and switching devices (3 phase units) IMPORTANT NOTE: The large electrical on/off switch on the plant is not considered as an isolator as there is still full load current going into one side of the unit to the switch through the power cable;... -
Page 12: Further Installation For Units With An External Ultrasonic Generator
When all these conditions are satisfied, the unit is ready for filling. As major suppliers of cleaning systems, Guyson International Limited have wide experience in solving problems and will be pleased to give assistance to any purchaser of their equipment requiring help in any matter concerning installation. -
Page 13: Operating Instructions
Operation & Maintenance Manual 4. Operating instructions 4.1 Filling of the unit The appropriate safety precautions must be taken when filling the bath with cleaning solution (see section - Safety). As previously stated, the KS MK3 & UCR MK3 units are designed for use with neutral or mildly alkaline aqueous cleaning solutions. -
Page 14: Control System
Operation & Maintenance Manual 4.2 Control system The control system on the unit allows adjustment of the times and temperatures via the membrane control panel. 4.2.1 Layout of the membrane panel display All settings and readings are made via the membrane control panel. The layout of the membrane panel is shown below with each of the main areas labelled. -
Page 15: Led Status And Fault Indication
Operation & Maintenance Manual 4.2.2 LED status and fault indication The LED’s on the control panel illuminate in different formats to show the status of the unit as follows: Colour of LED Type of illumination Meaning YELLOW solid Mains power is applied to the unit. -
Page 16: Lcd Display Screens
Operation & Maintenance Manual 4.2.3 LCD display screens The operator can progress through the various LCD screens by pressing the select button to go to each next screen as follows: Screen Reference Example of What is shown? digits Screen 1 Sonics cycle time countdown (press SELECT for next screen) Screen 2... - Page 17 Operation & Maintenance Manual 4.2.4 Control panel push buttons and indications If tank 1 or tank 2 has a low level sensor/s fitted and if either of the tanks levels drops below the level sensor, the relevant ‘low level reset’ button will illuminate and the tank will require topping up with solution.
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Page 18: Start Up
Operation & Maintenance Manual 4.3 Start up Ensure that all the conditions detailed in sections are met. Switch the power on. When Mains power is first applied, the sonics and heaters will not be energised. The PWR LED will illuminate. In order to enable the heaters, a single press of the <START> key is required. At all times, the HEAT LED will flash when the heaters are enabled and the temperature is below the set point. -
Page 19: Operation
4.4.1 Using baskets All parts should be cleaned in Guyson International Limited baskets. The correct baskets are available from Guyson International Limited Service Dept. NOTE: Use of the incorrect basket or component carrier may cause damage to the tank. -
Page 20: Setting The Heating Temperature
Operation & Maintenance Manual 4.5 Setting the heating temperature The temperature may be set in the range 20°C to 80°C in 1 degree increments. An over-temperature condition for shutdown in the event of any failure is maintained at the current set point plus 10°C. -
Page 21: Setting The Sonics Time
Operation & Maintenance Manual 4.6 Setting the sonics time The sonic cycle time may be set while the sonics are off by using Screen 3 of the LCD display (see below table). Screen Reference Example of What is shown? digits Screen 1 Sonics cycle time countdown (press SELECT for next screen) -
Page 22: Shutdown
If an external Ultrasonic Generator is fitted, also switch off the generator and unplug from the mains socket. Where a lid is supplied it should be left in position. (Lids and baskets are available from Guyson International Limited Service Dept. - see next section.) 4.8 Ancillary parts... -
Page 23: Description
NOTE: For information on the generator please see the generator manual (located at the back of this manual). In addition, a system could include a pump and filtration unit (KPF60), Guyson component carrier or baskets and a Guyson tank lid. -
Page 24: The Ks Mk3 Range Of Ultrasonic Cleaning Tanks
Mat heaters provide the heating (see specification overleaf). A socket at base level provides a drain facility and a further socket at 50mm (KS MK3 300, KS MK3 450, KS MK3 525) or 100mm (KS MK3 1500 and above) below nominal liquid level allows the fitment of an optional KPF60 filtration module. -
Page 25: Ks Mk3 Range Technical Specification
Operation & Maintenance Manual 5.2.1 KS MK3 range technical specification KS MK3 TYPE KS MK3 300 KS MK3 450 KS MK3 525 KS MK3 KS MK3 KS MK3 1500 3000 4000 TANK SIZES Width (mm) 1000 Front to Rear (mm) -
Page 26: The Ucr Mk3 Range Of Ultrasonic Clean And Rinse Tanks
A hand held spray wand is supplied and will be located in the top surround at the rear and to the right of the rinse tank. This may have an optional connection for a DI water supply. Provision is made for top hanging baskets - (the baskets must be ordered separately from Guyson International). -
Page 27: Ucr Mk3 Range Technical Specification
Operation & Maintenance Manual 5.3.1 UCR MK3 range technical specification UCR MK3 TYPE UCR MK3 UCR MK3 UCR MK3 UCR MK3 1500 TANK SIZES Width Front to Rear Effective Depth Tank Effective Capacity (litres) 17.5 36.5 59.9 OVERALL EQUIPMENT SIZES Width 1060 1260... -
Page 28: Optional Pumping And Filtration Unit
Operation & Maintenance Manual 5.4 Optional pumping and filtration unit The KPF60 pumping and filtration unit is available as an option for the UCR and KS MK3 Range of Ultrasonic cleaning Tanks. The pumping action is provided by a March May TE5i-PMD pump and the filtration components consist of a polypropylene coarse strainer and polypropylene removable cartridge fine filter with filter quality pressure monitor gauge. -
Page 29: Baskets
New baskets are compatible with this design and are backwards compatible with the existing range. Existing old baskets are not forwards compatible. If you have old baskets you can contact Guyson International Limited Service Department for a simple minor modification of the basket. -
Page 30: Electrical Circuit And Control Systems
Operation & Maintenance Manual 6. Electrical circuit and control systems 6.1 Power requirements table In general the systems described in this manual are designed to work at 230V ac single phase + neutral and earth. However, some larger systems may have a 3 phase supply and some special systems may be configured at a different voltage specific to their place of use. -
Page 31: Thermal Shock
Operation & Maintenance Manual 6.3 Thermal shock To avoid thermal shock to the transducers, never pour hot liquids into a cold tank or vice versa. When filling a hot or cold tank, fill it approximately ¼ full with liquid of a similar temperature to that of the tank and complete the filling using either hot or cold liquid as required. -
Page 32: Fuse Replacement (On Single Phase Units)
1. Isolate unit from power supply (remove mains plug from mains socket on single phase units). 2. Unscrew the fuse holders. 3. Replace with correct fuses: 1 1/4" ceramic quick acting fuses (rating 220-240V) as follows: Model Fuse/MCB KS MK3 300 KS MK3 450 12.5A KS MK3 525 12.5A KS MK3 1500... -
Page 33: Resetting Of Mcb's (On 3 Phase Units)
Operation & Maintenance Manual 6.5 Resetting of MCB's (on 3 phase units) Tanks of sizes from 1500 upwards are 3 phase units. KS MK3 & UCR MK3 3 phase units have 3 MCB's (for the main power). In order to reset the MCB's: 1. -
Page 34: Cleaning Solutions
Strict compliance with the manufacturer’s recommendations in respect of the use of the specified cleaning solution is necessary at all times. Guyson International Ltd should be contacted for advice if any change to the original cleaning solution specified is contemplated. -
Page 35: Maintenance
Guyson International. In all cases where the cause of failure is uncertain, reference should be made to Guyson International Limited. The following schedules list the tasks that must be carried out, but the frequency of their implementation will be determined by the working environment of the machine, e.g. -
Page 36: Routine Preventative Maintenance
Check liquid level is above the minimum liquid level line and, if required, add further cleaning solution. • If the MCB regularly trips out, this should be investigated by a qualified electrician or Guyson Service Engineer. • If the generator board is not responding contact Guyson Service Dept. -
Page 37: Weekly
Operation & Maintenance Manual 8.2.2 Weekly • Coarse filter: Close the isolation valves then unscrew and remove bowl and filter assembly. Pour solution into correct tank then clean bowl and filter. Re-assemble in reverse order ensuring that the ‘O’ ring seal is suitable for re-use (if in doubt replace) and is correctly located. -
Page 38: Draining And Cleaning The Plant
Operation & Maintenance Manual 8.3 Draining and cleaning the plant As work is being processed, cleaning results may begin to deteriorate because of the progressive build up of solid contamination. Once this stage is reached the plant will need to be drained and cleaned. -
Page 39: Trouble-Shooting Guide
Unit not working Power failure Check mains supply and all associated fuses. Sonics do not come on Generator board failure Return unit to Guyson International Ltd. for repair. Failure of relay for membrane panel Generator(s) not working Generator fuse blown... -
Page 40: Principles & Advantages Of Ultrasonic Cleaning
Operation & Maintenance Manual 9. Principles & advantages of ultrasonic cleaning 9.1 Basic principles of ultrasonic cleaning The key operation associated with this equipment is ultrasonic cleaning, so to give an understanding of the machine’s operation, the principles of this technique are now described. Ultrasonic cleaning depends upon the phenomena associated with acoustic cavitation. -
Page 41: Advantages Of Ultrasonic Cleaning
Operation & Maintenance Manual 9.2 Advantages of ultrasonic cleaning Ultrasonic cleaning systems achieve extremely high standards of cleanliness in a fraction of the time required to obtain the same results by conventional methods such as hand cleaning, spray washing or similar mechanical means. -
Page 42: Primewave Ultrasonic Generator Manual (Ks 3000 & Ks 4000 Only)
10. Primewave Ultrasonic Generator Manual (KS 3000 & KS 4000 only) Guyson International Limited Snaygill Industrial Estate Keighley Road Skipton North Yorkshire BD23 2QR Tel: 01756 799911 E-mail: info@guyson.co.uk Fax: 01756 790213 Website: www.guyson.co.uk... - Page 43 Operation & Maintenance Manual DI Cylinder & Conductivity Meter Installation Guidance for a UCR (Purite & Elga Cyclinders) Issue: DI Cylinder & Conductivity Meter Installation Guidance for a UCR Date: 10/2013 Page: 43...
- Page 44 Operation & Maintenance Manual Table of Contents 1. Water supplies and Drainage Connections on a UCR………………………………………………….45 2. Water treatment (Purite bottles) connections on a UCR machine……………………………………..46 3. Conductivity Meter Connections………………………………………………………………. ………….49 4. Manual fill and drain valves on a UCR machine…………………………………………………………51 Issue: DI Cylinder &...
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Page 45: Water Supplies And Drainage Connections On A Ucr
Operation & Maintenance Manual 1. Water supplies and Drainage Connections on a Spray lance water supply from Purite bottles. Mains water supply, Gravity Drain town’s water Issue: DI Cylinder & Conductivity Meter Installation Guidance for a UCR Date: 10/2013 Page: 45... -
Page 46: Water Treatment (Purite Bottles) Connections On A Ucr Machine
Operation & Maintenance Manual 2. Water treatment (Purite bottles) connections on a UCR machine Bleed nipple. Press to release the trapped air. Pipe Locate pin. Pull out to release pipe connections. Issue: DI Cylinder & Conductivity Meter Installation Guidance for a UCR Date: 10/2013 Page: 46... - Page 47 Operation & Maintenance Manual Top = Inlet Bottom = Outlet The outlet of the water treatment bottle is connected to the spray lance. Carbon cylinder Mains water supply. Deionising cylinder Issue: DI Cylinder & Conductivity Meter Installation Guidance for a UCR Date: 10/2013 Page: 47...
- Page 48 Operation & Maintenance Manual For installation of the Elga cylinders for a UCR tank, see below: Connect the small Connect the last section section of hose from of hose from the inlet of the outlet of the De- the conductivity metre to ionised cylinder to the spray lance inlet on the outlet on the...
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Page 49: Conductivity Meter Connections
Operation & Maintenance Manual 3. Conductivity Meter Connections The conductivity meter connections. Issue: DI Cylinder & Conductivity Meter Installation Guidance for a UCR Date: 10/2013 Page: 49... - Page 50 Operation & Maintenance Manual The conductivity meter test push button. Issue: DI Cylinder & Conductivity Meter Installation Guidance for a UCR Date: 10/2013 Page: 50...
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Page 51: Manual Fill And Drain Valves On A Ucr Machine
Operation & Maintenance Manual 4. Manual fill and drain valves on a UCR machine Manual fill valves If ‘weir to drain’ is necessary, the stage 2 drain valve must be fully Drain valves open and the stage 2 fill valve must be slightly open.